A grader’s cabin has been destroyed in the early hours of the morning at a New South Wales mine after colliding with a front-end loader that had its bucket raised.
It occurred when the driver of the front-end loader raised his bucket to protect his vision from the rising sun and continued travelling with limited visibility.
It then struck the grader driving in the opposite direction, with the grader’s driver suffering a minor laceration to the leg and bruising; they were transported to the hospital for routine assessment.
“The incident is a reminder that even routine tasks can become dangerous when visibility is compromised, and procedures aren’t followed,” the NSW Resources Regulator said.
The front-end loader driver, after passing the end of a divided section of the site’s haul road, said that a two-way communication call was made to the grader operator, who did not hear the call.
This call could also not be confirmed by others, said the resources regulator.
“As the loader turned in front of the grader, the operator took evasive action by turning to the left,” the state body said.
“Given the unexpected action of the loader and the short time frame, a collision could not be avoided.
“The loader initially made contact with the grader mid-way along the main structure, before hitting the rear right cabin pillar.”
All grader cabin supports were severed, and the cabin toppled to the left, resting on the front rear tyre.
During the investigation, a re-enactment of the scene found that the loader operator’s visibility was significantly obstructed when travelling with the bucket raised.
While the loader itself was mechanically sound, with a functioning two-way radio and clear windscreen, investigators determined the operator turned across the haul road while visibility remained restricted.
Critically, the site had procedures requiring loaders to operate with buckets lowered, but they were not consistently followed or enforced. Over time, workers and supervisors had normalised the practice of raising buckets to block sun glare.
The regulator also found the mine had not formally identified or controlled the risks associated with sun glare, instead allowing operators to determine their own mitigation measures in the field.
Additional gaps were identified in communication protocols, with no designated ‘call-up’ or ‘hold point’ signage in place to guide UHF radio use, leaving operators reliant on memory.
In response, the NSW Resources Regulator issued a prohibition notice preventing the operation of heavy mobile equipment with raised buckets where visibility is obstructed.
The mine operator was also directed to formally assess and implement controls for reduced visibility hazards, including those caused by sun glare.
NSW Resources urged mine operators to reassess their safety management systems, ensuring controls are not only documented but actively followed in practice.
The regulator further recommended improving vehicle separation strategies, installing clear signage for communication protocols, and ensuring equipment is used within its intended design parameters.
“Mine operators must identify all reasonably foreseeable hazards… and eliminate or minimise risks so far as is reasonably practicable,” NSW Resources said.
Subscribe to Safe to Work for the safety news that matters most to the Australian mining industry.